scholarly journals Experimental Study and Numerical Simulation of the Intermittent Feed High-Speed Grinding of TC4 Titanium Alloy

Metals ◽  
2019 ◽  
Vol 9 (7) ◽  
pp. 802 ◽  
Author(s):  
Jun Yi ◽  
Wei Zhou ◽  
Zhaohui Deng
Keyword(s):  
Numerical Simulation ◽  
Titanium Alloy ◽  
Surface Integrity ◽  
High Speed ◽  
Grinding Force ◽  
Grinding Wheel ◽  
Grinding Temperature ◽  
Tc4 Titanium Alloy ◽  
High Speed Grinding ◽  
Feed Mode

This paper proposes intermittent feed high-speed grinding, which shows considerable advantages in terms of reducing grinding temperature, relieving grinding wheel blockage and improving workpiece surface integrity. In this grinding, the continuous feed mode of the workpiece is changed into the normal feed + fast retreat reciprocating feed mode by a fast linear feed worktable. By reasonably setting the normal feed distance of single grinding, the action time of the grinding wheel and workpiece is reduced, so that the grinding heat transfer process does not reach a stable state, reducing the grinding temperature during single grinding. Besides this, the surface temperature is cooled to nearly room temperature and the grinding wheel is flushed by the timely retreating of the grinding wheel to allow the grinding fluid to enter the grinding zone fully, which greatly reduces the phenomenon of heat accumulation and grinding wheel loading. An intermittent feed high-speed grinding experiment on Ti-6Al-4V (TC4) titanium alloy was systematically carried out, and the influence of the grinding parameters on grinding force and grinding temperature was deeply analyzed. The instantaneous grinding temperature field and thermal stress field of TC4 titanium alloy in intermittent feed high-speed grinding were constructed with the finite element method. The surface morphology of the grinding wheel and TC4 titanium alloy specimens after intermittent feed grinding were analyzed and were compared with those after traditional continuous grinding. It was found that the curves of the grinding force and temperature varied with time in the process of machining, consisting of many “pulse” peaks. Under the same grinding parameters, the magnitude of the grinding force is the same as that of continuous grinding. In a certain range, the grinding temperature is greatly affected by the single feed distance and the interval time. The numerical simulation results are in good agreement with the experimental results, and the error is controlled within 12%. Compared with traditional high-speed grinding, under the same process parameters, the grinding temperature is greatly reduced, the surface integrity of the workpiece is better, and the clogging of the grinding wheel is greatly reduced.

Study on Effect of Grinding Fluid Supply Parameters on Surface Integrity in Quick-Point Grinding for Green Manufacturing

2008 ◽  
Vol 53-54 ◽  
pp. 209-214 ◽  
Author(s):  
Shi Chao Xiu ◽  
Ya Dong Gong ◽  
Guang Qi Cai
Keyword(s):  
Surface Integrity ◽  
High Speed ◽  
Point Contact ◽  
Green Manufacturing ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Grinding Fluid ◽  
Fluid Supply ◽  
High Speed Grinding ◽  
Grinding Power

In high and super-high speed grinding process, there is an airflow layer with high speed around the circle edge of the grinding wheel that hinders the grinding fluid into contact layer, namely, the air barrier effect. The speed of airflow layer is directly proportional to the square of the wheel speed. Quick-point grinding is a new type of high and super-high speed grinding process with a point contact zone and less grinding power. The edge effect of the air barrier is weakened because the thin CBN wheel is applied in the process. By the analysis of dynamic pressure and velocity distributions in the airflow layer around the wheel edge, the mathematic models of the flow and jet pressure of grinding fluid for effective supply in the process were established and the process of optimization calculation of the jet nozzle diameter for green manufacturing was also analyzed based on the thermodynamics and the technical character of quick-point grinding process. The quick-point grinding experiment for surface integrity influenced by grinding fluid supply parameters was performed.

Investigation of Surface Integrity on TC4-DT in High Speed Grinding with CBN Wheel

2014 ◽  
Vol 1027 ◽  
pp. 140-145
Author(s):  
Yao Guang Chen ◽  
Wen Zhuang Lu ◽  
Jun Xu ◽  
Yan Song Zhu ◽  
Dun Wen Zuo
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
High Speed ◽  
Linear Velocity ◽  
Grinding Wheel ◽  
Cbn Wheel ◽  
Increasing Trend ◽  
High Speed Grinding ◽  
Weak Influence ◽  
Quality Surface

A series of grinding experiments were carried out with CBN wheel to focus on the surface integrity of titanium alloy TC4-DT in high speed grinding . In order to get the proper process parameters to control the surface integrity of the TC4-DT, surface roughness, subsurface morphology and microhardness variations have been studied. In addition to the use of CBN wheel, scanning electron microscopy (SEM), 3-d contour instrument and microhardness tester was applied. The results show that the surface roughness is decreased obviously when grinding wheel linear velocity rises from 60m/s to 80m/s. While the grinding speed rises from 80m/s to 100m/s, the surface roughness value increases slightly. Moreover, the surface roughness value increases with the grinding depth and the increasing trend is obvious in the process of machining. The microstructure analysis shows that during high speed grinding with CBN wheels, good quality surface with 10μm grinding depth can be obtained. Table feed rate has weak influence on the grinding surface topography. The microhardness analysis indicates that surface microhardness increases sharply with the increasing of grinding wheel linear velocity in high speed grinding.

A Practical Study on the Surface Integrity of High-Speed Cylindrical Grinding of SiC

2012 ◽  
Vol 723 ◽  
pp. 202-207
Author(s):  
Jia Ming Ni ◽  
Bei Zhi Li ◽  
Jing Zhu Pang
Keyword(s):  
Surface Integrity ◽  
High Speed ◽  
Ground Surface ◽  
Surface Damage ◽  
Grinding Wheel ◽  
Force Model ◽  
X Ray Diffraction ◽  
High Speed Grinding ◽  
Machining Rate ◽  
Grinding Efficiency

In order to reconcile the contradiction between the ceramic grinding efficiency and surface integrity, high-speed grinding with diamond grinding wheel is supposed to be a solution. In this paper, first of all, a normal grinding force model is proposed based on the consideration of the material property and the grinding process parameters. It can be seen that an elevated grinding wheel velocity in combination of a higher workpiece speed can increase the machining rate while maintaining the desired surface integrity. After a series of grinding tests, a comprehensive measurement has been done to study the surface damage by the surface roughness, the microscope profile and the X-ray diffraction. In particular, the effect of the grinding parameters on the ground surface are analyzed and reported.

scholarly journals Grinding Force and Heat of Titanium Alloy Abrasive Belt and Its Effect on Surface Integrity

2021 ◽  
Author(s):  
Ying Liu ◽  
Jiayu Xu ◽  
Guijian Xiao ◽  
Kun Zhou ◽  
Gang Liu
Keyword(s):  
Titanium Alloy ◽  
Surface Quality ◽  
Surface Integrity ◽  
Grinding Force ◽  
Maximum Temperature ◽  
Grinding Process ◽  
Feed Speed ◽  
Grinding Temperature ◽  
Linear Speed ◽  
Abrasive Belt

Abstract Key rotating parts such as integral blisks and blades of aero-engines are widely made of titanium alloys. Abrasive belt grinding is one of the effective methods to improve the surface integrity. However, the grinding process produces greater grinding force and higher Grinding temperature,which have an impact on surface quality. At present, the force-heat coupling relationship in the grinding process and its influence on surface quality have not been explored. In this paper, a titanium alloy belt experiment is carried out to detect the force and temperature in the grinding process, this paper explores the influence of the grinding process parameters on the grinding force and temperature, and analyzes the influence on surface integrity of the force and temperature in the grinding process. The results show that the decrease of the belt linear speed, the increase of the feed speed and the grinding depth leads to the increase of the grinding force, the decrease of the feed speed, the increase of the belt linear speed and the grinding depth cause the temperature to rise. The effect of grinding depth on grinding force and grinding temperature is the most significant. And High grinding force and grinding temperature will cause the surface quality to deteriorate and even more serious defects. However, when the maximum temperature of the grinding temperature field reaches above 120°C, the surface roughness of the workpiece decreases from 1.596μm to 1.093μm, and the height of the surface undulation is reduced from 32μm to 19μm. This paper provides a reference for improving the surface integrity of the grinding process.

Experimental Investigation on High-Speed Grinding of 40Cr Steel with Vitrified CBN Grinding Wheel

2010 ◽  
Vol 126-128 ◽  
pp. 154-158 ◽  
Author(s):  
Jian Wu Yu ◽  
Tao Chen ◽  
Zhen Tao Shang ◽  
Xiao Min Sheng ◽  
Gui Zhi Xie
Keyword(s):  
Surface Roughness ◽  
Experimental Investigation ◽  
Feed Rate ◽  
High Speed ◽  
Grinding Force ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
High Speed Grinding ◽  
Cbn Grinding Wheel ◽  
Vitrified Cbn

This paper focuses on experimental investigation on high speed grinding of 40 Cr steel with vitrified CBN grinding wheel, the effect of grinding process parameters, such as grinding speed, depth of cut, and feed rate, on the grinding force and surface roughness are analyzed The experimental results reveal that the grinding force decreases with higher grinding speed and increases with the addition of depth of cut or feed rate, and the surface roughness is satisfactory in high speed grinding.

Experimental Research of Grinding Force and Specific Grinding Energy of TC4 Titanium Alloy in High Speed Deep Grinding

2009 ◽  
Vol 76-78 ◽  
pp. 55-60 ◽  
Author(s):  
Xiao Min Sheng ◽  
Kun Tang ◽  
Jian Wu Yu ◽  
Hai Qing Mi
Keyword(s):  
Titanium Alloy ◽  
Material Removal ◽  
High Speed ◽  
Removal Rate ◽  
Chip Thickness ◽  
Grinding Force ◽  
Specific Grinding Energy ◽  
Undeformed Chip Thickness ◽  
Tc4 Titanium Alloy ◽  
Grinding Power

Focusing on the characteristic of hard-to-grind for titanium alloy, experiments were conducted about grinding TC4 titanium alloy under high speed deep grinding (HSDG) condition. The changing of grinding force per unit area with maximum undeformed chip thickness hmax and equivalent cutting thickness aeq are analyzed in this paper. The effect of maximum undeformed chip thickness hmax and specific material removal rate Zw' on specific grinding energy es, material removal mechanism and consumption of grinding power in HSDG process are also discussed. The experiment results reveal that application of HSDG can improve machining efficiency of grinding TC4.

Analysis on Surface Temperature Field of Ultra-High Speed Grinding

2006 ◽  
Vol 304-305 ◽  
pp. 131-135 ◽  
Author(s):  
S.X. Yuan ◽  
Wen Yuan Tian ◽  
Guang Qi Cai
Keyword(s):  
Temperature Field ◽  
Theoretical Model ◽  
High Speed ◽  
Grinding Force ◽  
Grinding Temperature ◽  
Temperature Model ◽  
Workpiece Material ◽  
Ultra High Speed ◽  
High Speed Grinding ◽  
Surface Temperature Field

In this paper a theoretical model of grinding force in Ultra-high speed grinding (UHSG) is deduced. Considering the strength decreasing and softening of workpiece material after it is heated, the theoretical formulae for calculating grinding force are established. Qualitative analysis is proceeded on the proportion coefficient changing with the increase of grinding speed. At last, some simulative calculations are proceeded according to grinding temperature model and some useful conclusions are obtained.

scholarly journals SEAM-ECM Jet Milling TC4 Titanium Alloy Using Gas-Liquid Mixed Medium

2021 ◽  
Author(s):  
Shengsheng Zhang ◽  
Lizhong Wang ◽  
Jianping Zhou ◽  
Xiangyu Dai ◽  
Yan Xu ◽  
...  
Keyword(s):  
Electrical Conductivity ◽  
Titanium Alloy ◽  
Flow Field ◽  
Surface Integrity ◽  
High Speed ◽  
Electrochemical Machining ◽  
Machining Performance ◽  
Tc4 Titanium Alloy ◽  
Gap Flow ◽  
Mixed Medium

Abstract A novel combined machining approach combining short electric arc machining and electrochemical machining (SEAM-ECM) is proposed in this study. It aims to improve the surface integrity of TC4 titanium alloy by adding compressed air and electrolyte into the SEAM. This approach can change the material removal mechanism of the conventional SEAM and improve the gap flow field distribution and discharge state using the dual fluid properties of electrolyte and air mixed medium. The effects of gas addition on the state of the gap flow field and the electrical conductivity of the mixed medium are illustrated by flow field simulation. The effects of the presence or absence of air and the electrical conductivity of the solution on the machining performance are compared by experiments. The results show that the recast layer is weakened by using electrolyte and air mixed medium in SEAM-ECM compared to SEAM alone. The addition of high-speed air reduces defects such as melt drops, particles, holes. It performs with higher precision and finishes than ECM alone, the overall surface integrity has been significantly improved.

Study on Edge Contact Area and Surface Integrity of Workpiece in Point Grinding Process

2009 ◽  
Vol 407-408 ◽  
pp. 577-581
Author(s):  
Shi Chao Xiu ◽  
Zhi Jie Geng ◽  
Guang Qi Cai
Keyword(s):  
Surface Integrity ◽  
Contact Area ◽  
High Speed ◽  
Ground Surface ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Edge Contact ◽  
Cylindrical Grinding ◽  
Theoretic Foundations

During cylindrical grinding process, the geometric configuration and size of the edge contact area between the grinding wheel and workpiece have the heavy effects on the workpiece surface integrity. In consideration of the differences between the point grinding and the conventional high speed cylindrical grinding, the geometric and mathematic models of the edge contact area in point grinding were established. Based on the models, the numerical simulation for the edge contact area was performed. By means of the point grinding experiment, the effect mechanism of the edge contact area on the ground surface integrity was investigated. These will offer the applied theoretic foundations for optimizing the point grinding angles, depth of cut, wheel and workpiece speed, geometrical configuration and size of CBN wheel and some other grinding parameters in point grinding process.

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